Crown split sizing mechanism

ABSTRACT

The disclosure relates to headwear, the headwear including a crown and a size adjusting mechanism including a crown slit comprising a first terminal crown edge and a second terminal crown edge and extending continuously from a slit termination site of the crown through a bottom circumferential edge of the crown, where the first terminal crown edge and the second terminal crown edge are configured to overlap by a greater or lesser extent as a size of the crown is adjusted via the size adjusting mechanism.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Application 63/029,279, entitled “Crown Split Sizing Mechanism,” and filed on May 22, 2020. The entirety of the above-listed application is hereby incorporated by reference for all purposes.

FIELD

The disclosure relates to headwear including a size adjusting mechanism.

BACKGROUND AND SUMMARY

Headwear may be utilized to shield a wearer from environmental hazards, such as sunlight, debris, rain, etc. Headwear may be manufactured as “fitted” (e.g., where the same headwear is manufactured having different dimensions to accommodate different wearer head sizes) or “one size fits all.” Fitted headwear may incur additional manufacturing costs over one size fits all headwear, as each size/dimension configuration may be manufactured separately, thereby decreasing batch manufacturing efficiency. One size fits all headwear may include adjustment mechanisms in order to accommodate different wearer head sizes. Size adjusting mechanisms may be limited to only adjusting a small portion of the headwear (e.g., a headband or bottom portion of a crown of the headwear), which may not address sizing issues in other regions of the headwear and which may lead to unsightly bulging of excess material in regions of the headwear.

The present disclosure provides headwear that includes a crown split sizing mechanism that is configured to adjust a size of the crown. The sizing mechanism includes a crown slit that extends continuously from an apex (or near the apex) to (and through) a bottom circumferential edge of the crown. The crown material on both sides of the crown slit may overlap to a greater or lesser extent during associated sizing adjustments of the sizing mechanism, thereby allowing the headwear to be sized to fit a variety of head sizes while still providing the sun protection afforded by a crown without any gaps or bulging material.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be better understood from reading the following description of non-limiting embodiments, with reference to the attached drawings, wherein below:

FIG. 1 is a front view of a hat in accordance with an example of the present disclosure.

FIG. 2 is a left side view of the hat of FIG. 1.

FIG. 3 is a right side view of the hat of FIG. 1.

FIG. 4 is a back view of the hat of FIG. 1 showing adjustable sizing features of the hat.

FIG. 5 is a top view of the hat of FIG. 1.

FIG. 6 is an isometric side view of a portion of the hat of FIG. 1 showing distinct features of the crown.

FIG. 7 is a bottom/interior view of the hat of FIG. 1.

FIG. 8 shows a close-up bottom/interior view of the crown of the hat of FIG. 1.

FIG. 9 shows an interior view of the hat of FIG. 1, wherein the hat is held opened/unfastened.

FIG. 10 shows a close-up interior view of the crown of the hat of FIG. 1, wherein the crown is held opened.

FIGS. 11A-11D show example rear views of the hat of FIG. 1 in different stages as the hat is resized.

FIG. 12 shows an alternative embodiment of the hat of FIG. 1 with a continuous crown that can overlap when the hat is resized.

DETAILED DESCRIPTION

The present disclosure provides for headwear (e.g., a hat) that includes a crown split size adjusting mechanism including a slit in a rear of the headwear extending through an outer edge of a crown up to or near the top of the crown, the crown being configured with one or more fasteners to provide hat sizing flexibility. The size adjusting mechanism allows the rear panels of the crown of the headwear to overlap to a greater or lesser extent during associated sizing adjustments, and removes any unsightly bulging or puckering of excess material. In some examples, the headwear may include a brim that extends around an entirety of the crown and is relatively sturdy, such that the brim is maintained away from a wearer's face and neck, thereby allowing for adequate air circulation while still providing sun protection to the wearer's face, neck, ears, etc. The brim may include a brim slit that is joined with the crown slit, which may allow the brim to overlap to a greater or lesser extent along with the crown during size adjustment.

The slit may be formed from two overlapping crown edges at the rear of the crown and (in some examples) two overlapping brim edges at the rear of the brim. The overlapping crown edges are movable relative to one another as a size of the crown is adjusted Likewise, the overlapping brim edges are movable relative to one another as the size of the crown is adjusted. The crown and brim may be held in place once brought to a desired crown size via one or more fasteners.

Front and side views of an example hat are shown in FIGS. 1-3. The hat includes a crown and may optionally include a crown band, a brim, and an optics holder. The back of the hat with a size adjusting mechanism comprising a crown slit and a brim slit is shown in FIG. 4. Different panels of the crown and size adjusting mechanism are further shown in FIGS. 5 and 6. The interior of the hat with a fastening mechanism is shown in FIGS. 7-10. FIGS. 11A-11D show example rear views of the hat of FIG. 1 in different stages as the hat is resized. FIG. 12 provides an alternative embodiment of the hat with a continuous crown that retains an ability to overlap when the hat is resized.

FIG. 1 shows a front view of an example hat 100 including a hat body 102. FIG. 2 and FIG. 3 show a left side view and a right side view of the hat described in FIG. 1, respectively. FIGS. 1-3 are collectively described herein. The hat body 102 includes a multi-paneled crown 104 that is configured to extend over a top of a wearer's head. In some embodiments, the crown 104 may include a plurality of panels extending around a circumference or perimeter of the crown and intersecting at a central region (e.g., a top of the crown). In the illustrated example, the crown may include a front panel 121, two side panels 122 and 123, and a rear panel 124. However, in other examples, the crown may be formed of a unibody construction (e.g., a single piece of material), may include pleats, and/or may include a different number of panels (e.g., six panels, five panels). In some examples, each panel (or the entirety of the crown) may include the same type of fabric or other material. In other embodiments, one or more panels may include a different type of material than the other panels. The fabric material may include wool felt, peachbloom, fur felt, parasisal, cotton, polyester, silk, and/or other suitable materials. The front panel 121 and/or the outer material of front panel 121 may be secured to the surrounding panels 122, 123 and 124 via respective stitching along each side of the panel or by another suitable securing mechanism. In some examples, the front panel 121 may be the same size as the side panels 122 and/or 123 or the rear panel 124. In other examples, the front panel 121 may be a different size (e.g., larger or smaller) than the side panels 122 and/or 123 or the rear panel 124.

As shown, the hat body 102 includes a crown band 108 that forms the bottom portion of the crown 104. The crown band 108 curves around a circumference of the hat body and may include the same or different type of material as the crown 104. The crown band 108 may include one or more pairs of optics holders, configured to secure eyewear or other objects to a front of the headwear. For example, a slit 112 a and a slit 112 b may be present along the sides of the crown band 108 providing access to one or more pockets. The pockets may be configured to house a portion of an earpiece or other structure of an optical device (e.g., sunglasses, eyeglasses, safety glasses, goggles, etc.). It is to be understood that any number or combination of slits and pockets may be used to secure optics or other objects to the hat. In some examples, the optics holders may utilize various venting slit sizes/segmentations and possible liners to make the eyewear “lock” in more securely. For example, a horizontal stitching may be provided across the slit to create a more secure holding mechanism for the optics when housed in a given pocket. The segmentation of the slits may also provide differently sized openings for differently sized optics. Furthermore, the segmentation of the slits may enable earpieces or other frame elements to be inserted relatively high on the crown of the hat (e.g., in an uppermost opening, above a horizontal stitch) or relatively low on the crown of the hat (e.g., in a lowermost opening, below a horizontal stitch and the uppermost opening). For example, sunglasses with larger frames/lenses may be inserted into an uppermost opening of the slit in order to allow the bottom of the sunglasses lenses/frames to rest on the brim of the hat. Additionally or alternatively, slits may be positioned in any suitable location or configuration on the headwear. For example, the slits may be positioned higher or lower on the crown, spaced further apart from/closer to one another, shifted along a circumference of the crown, and/or otherwise repositioned relative to the illustrated example without departing from the scope of this disclosure. In some examples, one or both of the crown band and optics holders may be omitted. In examples where the crown band is omitted, each panel of the crown may extend to a bottom circumferential edge that may be coupled to a brim (explained below) or that may form a terminating edge of the hat.

The hat body 102 includes a brim 106 that extends from the crown band 108 and traverses around the entirety of the crown 104. The brim 106 may be coupled to the crown along a bottom circumferential edge of the crown band, or along a bottom circumferential edge of the crown (when the crown band is omitted). The brim 106 may include a sturdy material, e.g., foam, buckram, wheat straw, rush straw, jute, etc. In some embodiments, the sturdy material of the brim 106 may be lined with fabric. In some examples, stitching 110 of the brim 106 may run in concentric circles. In other examples, the stitching of the brim may include a variety of other shapes. The brim 106 may be angled downward relative to the crown 104 (e.g., when worn by a wearer, the brim may be positioned at an angle relative to the crown/crown band, where the angle is greater than 90° but less than 180°). The brim angle may provide enhanced sun protection relative to a straighter brim, at least in some examples.

As shown, the hat 100 includes an adjustable chin strap 114 to secure the hat on a user's head and/or allow the hat to hang on a user's back. The chin strap 114 may include a single string and adjustment mechanism that may be adjusted to change a tightness of the string around the user's chin/neck. In some embodiments, the chin strap may include two interlocking pieces with an adjustable fastening mechanism (e.g., via buckle, zipper, snap fastener, hook, buttons, etc.) The chin strap 114 may be attached to the interior of the hat in a permanent or semi-permanent manner (e.g., via stitching, gluing, and/or other coupling mechanisms). In yet other examples, the chin strap may be omitted completely from the hat.

The hat 100 may include a size adjusting mechanism in the form of a slit in the back of the headwear, the slit extending through the brim up to a position near the top of the crown and may be configured with a fastening mechanism to control the size of the headwear. The size adjusting features of the hat are shown in more detail in FIG. 4.

FIG. 4 shows a rear view 400 of the hat 100 including a size adjusting mechanism 401. The rear panel 124 of the crown 104 of the hat body 102 may include a crown slit 402 extending from the top of the crown 104 to the bottom of the crown. The crown slit 402 may extend through a bottom circumferential edge 403 of the crown 104. The bottom circumferential edge 403 of the crown may be the bottom edge of the crown band 108, as shown, or may be the bottom circumferential edge of the crown when the crown band is omitted. The bottom circumferential edge 403 may extend around the crown and at least in some locations may couple to the brim 106. The crown slit 402 divides the rear panel 124 of the crown 104 into two equal or unequal parts, such that the crown 104 and the crown band 108 are not circumferentially continuous. As shown, the rear panel 124 is comprised of a first rear panel 124 a and a second rear panel 124 b. The first rear panel 124 a may be configured to be positioned at least partially under the second rear panel 124 b. The crown slit 402 creates two terminal edges on the rear panel 124 of the crown 104, a first crown edge 420 (forming a terminal edge of the second rear panel 124 b) and a second crown edge (not visible in FIG. 4). The first crown edge 420 and the second crown edge are configured to overlap at least when the hat is in a closed position (as shown in FIG. 4). As shown in FIG. 4, the first crown edge 420 meets the bottom circumferential edge 403 at a right angle corner, though other configurations are possible, such as a rounded corner.

A lateral slit may extend through the brim 106, creating a brim slit 408. The brim slit 408 extends through the edge of the brim, such that the outer edge 416 of the brim is not continuous circumferentially. The brim has a first terminal brim edge 422 and a second terminal brim edge (not visible in FIG. 4) each extending from the outer edge 416 to the crown band 108 such that no part of the brim is circumferentially continuous. The first and the second terminal brim edges of the brim are configured to overlap when the hat is worn by a wearer, such that the second terminal brim edge is beneath the first terminal brim edge. The crown slit 402 and the brim slit 408 extend continuously such that an overall slit is formed that extends from the outer brim edge to the slit termination site. As shown, the brim slit and the crown slit are offset from each other such that an outer flap 430 of the crown band 108 overhangs the brim slit 408. The outer flap 430 creates a region in the crown band 108 that may be easier to be held by a wearer while fastening the hat. However, in some examples, the brim slit and the crown slit may be aligned. As mentioned previously, the brim 106 may be angled slightly downward, which may protect the neck of a user against the sun and help the brim edges lay flat/stay hidden. In some examples, the angling of the brim may not be uniform, for example the front of the brim may be angled at more of a right angle than the back of the brim.

In the illustrated example, the stitching 110 of the brim 106 runs in concentric circles, while stitching 414 at the brim slit 408 runs in a perpendicular fashion to the outer edge 416 of the brim. The stitching 414 may run parallel to the first terminal edge 422 of the brim 106. However, the stitching shown in the present disclosure is non-limiting, and other stitching patterns, including a lack of stitching, are possible without departing from the scope of the disclosure.

The fabric around the outer edge 416 of the brim 106 may be folded, such that some parts of the fabric go into the interior and/or exterior of the brim. In some examples, a folded-edge hem sewn with a running stitch may create the outer edge 416 of the brim 106.

At the crown slit, the crown may include two adjustable fasteners, an outer fastener 404 and an inner fastener (not visible in FIG. 4). The inner fastener is shown in FIGS. 7-9 and discussed in more detail below. The outer fastener 404 may couple a first region of the crown (herein the outer flap 430 of the crown band) to a second region 432 of the crown. In the illustrated example, the outer fastener 404 includes a snap for fastening. A common male piece 412 of the snap is positioned on the outer flap 430 (above the bottom circumferential edge 403 and adjacent first crown edge 420) and four female pieces 441, 442, 443, and 444 (female piece 444 is not visible in FIG. 4) of the snap are positioned on the second region 432 of the crown band (above the bottom circumferential edge 403). The male piece 412 of the snap engages with one of the female pieces of the snap to form a snap closure. A tightness of the crown may be adjusted based on which female piece 441, 442, 443, or 444 engages the male piece 412 of the snap. In the illustrated example, the male piece 412 is engaging the female piece 444 (not visible in FIG. 4) such that the female piece of the snap is beneath the male piece 412. While four female pieces are described herein, the hat may include more or fewer than four female pieces without departing from the scope of this disclosure. Further, rather than including one common male piece and multiple female pieces, the outer fastener may include one common female piece and multiple male pieces and/or the female piece(s) may be positioned on the first region of the crown with the male piece(s) positioned on the second region of the crown. In some examples, the outer fastener may comprise hook and loop fasteners, buttons, hook and eyelets, etc., instead of a snap.

The first terminal edge 422 and the second terminal edge of the brim 106 at the brim slit 408 may overlap a proportion of one another that changes as the hat is resized via the sizing mechanism. For example, when the outer fastener is adjusted so that the hat is a first, largest size, the terminal edges may overlap each other by a first, smaller amount. As the outer fastener is adjusted so that the hat is tightened into a smaller size, the terminal edges may overlap by a larger amount, and the portions of the brim adjacent the terminal edges may overlap as well. Additionally, the hat 100 may include a brim clip (not shown) that holds the non-continuous terminal edges of the brim 106 at outer edge 416 together when the brim clip is closed/fastened.

The crown band 108 (and/or the crown where the crown meets the brim if the crown band is omitted) may have a diameter that changes as a function of the outer fastener (e.g., the position of the male piece 412 relative to the female pieces). For example, a largest diameter D (shown in FIG. 1) of the crown band 108 is the diameter when the hat is held in place by the snap closure formed by coupling of the male piece 412 and the female piece 444. Accordingly, the diameter of the crown band decreases when the male piece 412 of the snap couples with the female piece 443, 442, or 441. The largest diameter D may range from 16 cm to 20 cm in one example (which may result in the crown band having a circumference that ranges from 50 cm to 62 cm). In another example, the crown band may have a largest diameter that ranges from 14 cm to 16 cm (e.g., if the hat is configured to fit on the head of a child). The brim 106 may have a width W (shown in FIG. 1) that may be at least 50% of the largest diameter D of the crown band. For example, if the largest diameter of the crown band is 20 cm, the width of the brim may be 10 cm or more. In the illustrated example, the diameter D of the crown band 108 is 17.5 cm when the snap is held closed with the male piece 412 and the female piece 444 coupled together, while the width of the brim is 10 cm. However, other brim dimensions are possible without departing from the scope of this disclosure, such as a brim that has a width that is less than 50% of the diameter of the crown band.

FIG. 5 shows a top view 500 of the hat 100 and FIG. 6 shows an isometric side view 600 of the hat 100. As illustrated, the crown 104 is formed of front panel 121, side panels 122 and 123, and rear panel 124. Front panel 121, side panels 122 and 123, and rear panel 124 are joined at a top center point or apex 502 of the crown 104. For example, front panel 121 is coupled to side panel 122 via a first seam, side panel 122 is coupled to second rear panel 124 b via a second seam, first rear panel 124 a is coupled to side panel 123 via a third seam, and side panel 123 is coupled to front panel 121 via a fourth seam. Further, second rear panel 124 b is also coupled to side panel 123 along a small portion of side panel 123 corresponding to an offset length 506, described below. Each of the first, second, third, and fourth seams join/intersect at the apex 502.

As appreciated by FIGS. 5 and 6, the crown slit 402 terminates at a slit termination site 504 which may be at the third seam between crown panels 123 and 124. The slit termination site 504 is offset from the apex 502 of the crown 104 in the example illustrated herein. The slit termination site 504 is offset from the apex in both the horizontal and vertical directions. As appreciated from FIG. 5, the slit termination site 504 is offset from the apex 502 in a first direction by an offset length 506. The offset length 506 may be a suitable length. In one example, the offset length 506 may be longer than a width 508 of a seam liner of the crown. For example, the offset length 506 may be equal to or greater than the width 508. In the example shown, the offset length 506 is twice the width 508. The slit termination site 502 may also be offset from the apex 502 in a second direction, perpendicular to the first direction. In the second direction, the slit termination site 502 may be offset from the apex 502 by a length that is half of width 508. However, the offset lengths described herein are exemplary, and the slit termination site 504 may be offset from the apex 502 by any suitable amount, or the crown slit may terminate at the apex 502.

When the hat is being worn, an arc of a specific length (e.g., along the length of the seam between crown panels) may be formed extending from the apex 502 down to the bottom circumferential edge 403 of the crown. An example arc length A is shown in FIG. 6. The offset length 506 of which the slit termination site 504 may be offset from the apex 502 may be 5-10% of the arc length A toward the crown band, in one example. In some examples, the offset length 506 may be 0-20% of the arc length A. Thus, in such examples, the crown slit 402 may extend along the arc for at least 80% of the arc length A. In still further examples, the offset length 506 may be greater than 20% of the arc length A, such as 30-50% or more of the arc length A.

As appreciated by FIGS. 4-6, when the hat is held closed by the snap fastener 404 in any of the four coupling positions formed by the male and the female pieces of the snap (described above), the two terminal edges of the crown 104 at the crown slit 402 overlap, so that there is no gap at the crown slit along the circumferential direction even in the largest closed position (shown in FIG. 4). Further, the edges of the crown at the crown slit (e.g., first crown edge 420) may not include additional reinforcing material and may comprise only the panel material with or without stitching. As a result, and as appreciated by FIG. 6, the terminal edges of the crown at the crown slit and where the terminal edges of the crown overlap are flexible, which may accommodate a range of head sizes and shapes and may increase comfort when the hat is worn. However, in some examples, the terminal edges of the crown at the crown slit and/or where the terminal edges of the crown overlap may be less flexible, such as by including reinforcing material, additional stitching, or the like. Further, in some examples, the terminal edges of the crown at the crown slit and/or where the terminal edges of the crown overlap may be rigid. For example, when the size adjusting mechanism described herein is incorporated in a hard hat or other more rigid headwear, some or all of the crown may be comprised of rigid material such as plastic, and this may include terminal edges of the crown at the crown slit and/or where the terminal edges of the crown overlap.

FIGS. 7-9 show a bottom/interior view of the hat 100, illustrating that front panel 121, side panels 122 and 123, and rear panel 124 are joined at an underside of the apex 502 of the crown 104. FIG. 7 is the interior view 700 of the hat 100, when the snap is held closed. FIG. 8 is a close-up interior view 800 of the crown 104 of the hat 100. The second crown edge 720 of the crown slit 402 and the second terminal edge 722 of the brim slit 408 are visible in the interior views of the hat. The bottom view of the hat includes the inner fastener 704. The inner fastener 704 may couple an inner flap 750 of the crown (herein located on the crown band 108, adjacent to the second crown edge 720) to a third region 756 of the crown. In the illustrated example, the inner fastener 704 includes a hook and loop mechanism for fastening. A first piece (not visible in FIGS. 7-9) of the inner fastener is positioned on the inner flap 750 and a second piece 752 of the inner fastener is positioned on the third region 756 of the crown. The first and the second pieces of the inner fastener engage with one another to form a closure. In the illustrated example, when the hat is held closed by the outer snap fastener 404, the inner flap 750 of the crown band created by the crown slit 402 may be held in place by the corresponding inner fastener 704. In some examples, the inner fastener may comprise a snap(s), button(s), hook and eyelets, etc., instead of the hook and loop fasteners described above. Further, in some examples, the inner fastener 704 may be omitted and the size adjusting mechanism may be held in place via the outer (e.g., snap) fastener. Similar to the exterior of the hat, the crown slit 402 and the brim slit 408 in the interior of the hat are offset from each other such that the inner flap 750 overhangs the brim slit 408. The inner flap 750 creates a region in the crown that may be easier to be held while fastening the hat.

FIG. 8 shows example seam liners. The seam liners include a first seam liner 802 and a second seam liner 804. The second seam liner 804 may be positioned on the first seam liner 802 at the apex 502, such that the two seam liners form a cross. Each seam liner may cover two respective seams between crown panels and extend continuously from the crown band at a first respective location, over the apex, and back to the crown band at an opposite side of the crown band. FIG. 8 shows the width 508 of a seam liner (each seam liner may have the same width) and the offset length 506, as described above. It will be appreciated from FIG. 8 that the slit termination site 504 is offset from the apex 502 on both the outer side of the crown and the inner side of the crown.

Thus, the crown 104 is comprised of three triangular panels (front panel 121 and side panels 122 and 123) and a rear panel 124 that is divided into two sub-panels (e.g., the first rear panel 124 a and the second rear panel 124 b), the optional crown band 108, and the seam liners 802, 804. The panels may terminate at the apex and are coupled to another respective panel via a seam, where each seam is covered by a seam liner. The crown band may extend circumferentially to define a bottom edge of the crown, and the crown band may be coupled to the brim. Further, the crown may include more than the four panels disclosed herein, such as five panels, six panels, etc.

FIG. 9 shows an interior view 900 of the hat 100 in an open position, wherein the two fasteners (e.g., inner and outer) are held opened/unfastened to show the terminal edges 720, 420 of the crown slit, the terminal edges 422, 722 of the brim slit, the inner flap 750, and the outer flap 430. The inner part of the crown band 108 may have a lining 760 comprised of fabric or another material, except for the regions where the fasteners are located. The lining 760 of the crown band 108 is visible in FIGS. 7-9. As appreciated from FIG. 9, the female pieces of the outer fastener may be spaced apart from the second terminal edge 720 by the inner flap 750.

Thus, the crown may include a first flap (e.g., outer flap 430) and a second flap (e.g., inner flap 750), with a first terminal crown edge (terminal edge 420) of the crown slit extending to a bottom circumferential edge of the crown at the first flap and a second terminal crown edge (terminal edge 720) of the crown slit extending to the bottom circumferential edge of the crown at the second flap. Additionally, the bottom circumferential edge of the crown is not coupled to the brim at the first flap or the second flap, but is coupled to the brim along the remainder of the crown band. As described, the crown band includes a top circumferential edge, and a crown portion (e.g., the crown panels and seam liners described herein) is coupled to the crown band along an entirety of the top circumferential edge. Both the bottom circumferential edge of the crown and the top circumferential edge of the crown band are not continuous and terminate at the crown slit. Both the first flap and the second flap overhang the brim, and the second flap overhangs the brim by a larger amount than the first flap.

While a four panel crown having a crown band and coupled to a brim that extends substantially around an entirety of the crown has been shown and described herein, other hat configurations including the size adjusting mechanism described herein are possible. For example, the crown may include more or fewer panels and/or may not include a crown band. Further, the hat may not include a brim that extends around an entire circumference of the crown. Rather, the hat may be a ball cap-style hat with only a front brim, or the hat may have another suitable brim configuration. In any of these alternate configurations, the size adjusting mechanism may include a crown slit as described herein, extending continuously from a crown slit termination site at or offset from the apex of the crown and through a bottom circumferential edge of the crown. The edges of the crown, at the crown slit, may overlap to a greater or lesser extent as the crown is resized. Once a desired size of the crown is reached, the crown may be held in place at the desired size with one or both of an inner fastener and an outer fastener positioned along a bottom of the crown at/near the crown slit.

FIG. 10 shows a close-up interior view 1000 of the crown of the hat 100 in an unfastened state with the crown edges 420 and 720 held apart. The slit termination site 504 of the crown slit includes a region 1005 of an overlapping material that is created by overlapping of the first crown edge 420 and the second crown edge 720 at the slit termination site 504. The region 1005 of overlapping material is mirrored on the outer and inner sides of the crown. As appreciated by FIG. 10, the second crown edge 720 of the crown slit in the interior of the crown extends up to the seam between side panel 122 and second rear panel 124 b. This region 1005 of overlapping material at the slit termination site 504 may help the crown of the hat lay flat and remain in a closed or mostly-closed position even when the inner and/or outer fasteners are not fastened closed and may prevent bulging of the crown when the inner and/or outer fasteners are fastened closed.

As described above, a hat is disclosed comprising a crown having a crown slit comprising a first terminal crown edge and a second terminal crown edge and extending from a slit termination site; and a brim coupled to the crown and extending around a circumference of the crown, the brim having a brim slit comprising a first terminal brim edge and a second terminal brim edge. The crown slit and the brim slit collectively form an overall slit that extends continuously from the slit termination site of the crown and through an outer brim edge of the brim of the hat. In some examples, the brim is comprised of a sturdy material and the crown is comprised of fabric.

As described, the crown of the hat may be comprised of a first panel and a second panel coupled to the first panel at a seam, wherein an inner side of the seam is covered by a seam liner, and the slit termination site is positioned at an edge of the seam liner.

The crown of the hat may further comprise an apex and the slit termination site may be offset from the apex. In some examples, the slit termination site may be offset from the apex in a first direction by more than a width of the seam liner and may be offset from the apex in a second direction by less than a width of the seam liner.

In some examples, the crown slit and the brim slit may not be aligned. The crown may include a crown band, the brim coupled to the crown via a bottom circumferential edge of the crown band. The crown band may include a first flap and a second flap, the first terminal crown edge extending to the bottom circumferential edge of the crown band at the first flap and the second terminal crown edge extending to the bottom circumferential edge of the crown band at the second flap. Additionally, the bottom circumferential edge of the crown band is not coupled to the brim at the first flap or the second flap. As described, the crown band includes a top circumferential edge and the crown portion is coupled to the crown band along an entirety of the top circumferential edge.

The hat further comprises an outer fastening mechanism and an inner fastening mechanism, a first portion of the outer fastening mechanism positioned on the first flap and a second portion of the inner fastening mechanism positioned on the second flap. The outer fastening mechanism may further include a third portion positioned at a first inner region of the crown band adjacent the second flap, and the inner fastening mechanism may further include a fourth portion positioned at a second inner region of the crown band adjacent the first flap. As described, when the first portion is engaged with the third portion and/or when the second portion is engaged with the fourth portion, the first terminal brim edge overlaps the second terminal brim edge and the first terminal crown edge overlaps the second terminal crown edge.

A further illustration of example resizing of the crown 104 of hat 100 is shown in FIGS. 11A-11D. FIGS. 11A-11D show the rear view of hat 100 as the size of the hat is adjusted via the size adjusting mechanism 401. The adjustable outer snap fastener 404 with the male 412 and the female 441, 442, 443, 444 pieces are shown. FIGS. 11B-11D show the portion of the outer snap fastener 404 of FIG. 11A resized to decrease an overall crown 104 sizing. In FIG. 11A, the example view 1100 shows the largest diameter of the crown band 108 (e.g., the diameter D described above) when the male piece 412 of the snap is coupled to the female piece 444. In this position the two terminal edges of the brim 106 at the brim slit 408 overlap a proportion of one another (e.g., 0.5-1 cm). In the example view 1102 of FIG. 11B, the hat is resized via the sizing mechanism by coupling the male piece 412 and the female piece 443. This may decrease the circumference of the crown band 108 by a suitable amount (e.g., 2 cm) and increase the overlapping of the brim at the brim slit 408 by a corresponding amount (e.g., 2 cm). In the example view 1104 of FIG. 11C, the hat is resized further by coupling the male piece 412 with the female piece 442. This may further decrease the circumference of the crown band 108 (e.g., by another 2 cm) and increase the overlapping of the brim at the brim slit 408 by another corresponding amount (e.g., 2 cm). In the example view 1106 of FIG. 11D, the hat may be re-sized to have the smallest crown band 108 circumference by coupling the male piece 412 with the female piece 441 such that the total reduction in the circumference of the crown compared to FIG. 11A is 6 cm. Accordingly, FIG. 11D may show the maximum possible overlap of the brim such that an additional overlapping region of 6 cm (compared to FIG. 11A) may be present when the hat is held closed. This non-limiting example includes the four female pieces of the snap being spaced apart equally. There may be other examples wherein the spacing between the female pieces of the snap may be different, in which case the circumference of the crown band 108 and the overlapping of the brim may change by differing amounts when the hat is adjusted according to the various resizing positions illustrated in FIGS. 11A-11D. Further, the example circumference reduction and brim overlap amounts provided above are exemplary, and other amounts are possible. As appreciated by FIG. 11D, when the male piece 412 is coupled with the female piece 441, the first crown edge 420 may be aligned with/overlap the seam between the rear panel 124 a and the side panel 123.

As appreciated by FIGS. 11A-11D, the circumference of the crown and the overlap of the terminal edges of the crown at the crown slit also change as the hat is resized. However, the change in circumference and overlap along the crown slit is not uniform due to the spherical shape of the crown. At the point where the crown meets the crown band (e.g., at the bottom circumferential edge of the crown), the circumference and overlap of the edges at the crown slit may change as described above. However, the circumference and amount of overlap may change by a smaller amount as the crown slit extends toward the termination site.

FIG. 12 shows an isometric rear view 1200 of an alternate embodiment of the hat 100. The isometric rear view 1200 shows the hat in an unfastened state with the crown edges 420 and 720, and the brim edges 422 and 722 of the size adjusting mechanism 401 held apart. Accordingly, the outer flap 430 of the crown 104 is shown uncoupled from the second region 432 of the crown 104, i.e., the outer fastener is not fastened closed. In this embodiment, the crown 104 and the brim 106 of the hat are coupled to a gusset 1202 that extends across the opening formed by the crown slit and the brim slit, such that the crown and the brim extend continuously (e.g., without having an opening at the slit) in a circumferential direction, yet the crown and brim retain the ability to overlap when the hat is resized.

As shown in the illustrated example, the first crown edge 420 and the second crown edge 720 formed by the crown slit 402 may be coupled together via the gusset 1202, such that the gusset 1202 may form an additional crown panel 1202 a of the crown 104. The crown panel 1202 a may be formed between the first rear panel 124 a and the second rear panel 124 b of the crown 104. The gusset 1202 may extend from the crown 104 towards the brim 106, such that the first terminal brim edge 422 and the second terminal brim edge 722 formed by the brim slit 408 may also be coupled together via the gusset 1202. Therefore, the portion of the gusset 1202 coupling the brim edges 422 and 722 may form a brim panel 1202 b of the brim 106. The panels 1202 a and 1202 b of the gusset 1202 may further be coupled to each other via a fifth seam 1210. The fifth seam 1210 runs along the bottom circumferential edge 403 of the crown 104. However, in some examples, the crown panel 1202 a and the brim panel 1202 b may be formed from a single piece of material (or layers of material) and the fifth seam 1210 may be omitted.

In the illustrated example, the gusset 1202 is a triangular piece of fabric that may be attached to the rear of the hat body 102 coupling the crown slit 402 and the brim slit 408, such that each of the crown 104 and the brim 106 of the hat body 102 extend circumferentially without any openings. As shown, a first edge 1206 of the gusset 1202 may extend along the first crown edge 420 and the first terminal brim edge 422. The first edge 1206 of the gusset 1202 may be attached to the first crown edge 420 and the first terminal brim edge 422 via stitching, gluing, and/or other coupling mechanisms. A second edge 1208 of the gusset 1202 may extend along the second crown edge 720 and the second terminal brim edge 722. The second edge 1208 of the gusset 1202 may be attached to the second crown edge 720 and the second terminal brim edge 722 via stitching, gluing, and/or other coupling mechanisms. The first edge 1206 and the second edge 1208 of the gusset 1202 may join at the slit termination site 504 (i.e., where the first crown edge 420 and the second crown edge 720 meet) at or near the apex 502 of the crown 104. A third edge 1204 of the gusset 1202 may run along the outer edge 416 of the brim 106, such that the outer edge 416 of the brim is continuous.

The gusset 1202 in this embodiment may have a width K near the third edge 1204 and a width M near the slit termination site 504. The gusset 1202 may be configured such that the width of the gusset 1202 may gradually taper moving from the brim 106 towards the crown 104. For example, the width of the gusset 1202 may decrease from the third edge 1204 to the slit termination site 504, such that the width K close to the third edge 1204 is the largest width and the width M close to the slit termination site 504 is the smallest width.

The fabric material of the gusset 1202 may include cotton, polyester, silk, and/or other suitable materials. The fabric of the gusset 1202 may be made of a less rigid and more flexible material than the material of the crown 104 and/or the brim 106, such that it may allow the gusset 1202 to bend or fold easily when the sub-panels of the rear panel 124 of the crown 104 overlap during hat resizing. In some examples, the fabric of the gusset 1202 may include an elastomeric material to provide a stretch-fit alternative. In examples where the gusset is made of an elastomeric material, the overall width of the gusset may be narrower than the width of a non-elastomeric gusset. Accordingly, the elastomeric gusset may not be required to fold on itself when the sub-panels of the rear panel 124 of the crown 104 overlap during hat resizing. Additionally, the elastomeric material of the gusset may be used to control hat resizing through stretch fit. In such examples, the snap fasteners may be completely omitted.

There may be several advantages of a hat with a continuous crown created by using a gusset 1202 that couples to the crown slit. For example, a continuous crown may provide full protection and coverage of the head of a wearer, when the hat is being worn by the wearer. At the same time, the flexibility of the gusset 1202 may allow overlapping of the first rear panel 124 a and the second rear panel 124 b of the crown 104 to enable resizing of the hat in the same way as described previously in FIGS. 11A-11D. In examples where the brim extends around an entirety of the crown and the gusset extends from the crown to the brim to couple to the brim slit, the flexibility of the gusset 1202 also allows overlapping of the terminal edges of the brim when the hat is resized. In other hat configurations such as a ball cap-style hat with only a front brim, the size adjusting mechanism may lack a brim slit. Accordingly, in those configurations, the gusset 1202 may be coupled only to the crown slit with the first gusset edge 1206 being attached to the first crown edge 420, the second gusset edge 1208 being attached to the second crown edge 720, and the fifth seam 1210 serving as the third edge of the gusset running along the bottom circumferential edge 403 of the crown 104.

As depicted in FIG. 12, the hat is shown in an unfastened/opened state, where the gusset 1202 is fully exposed and extended indicating the maximum possible circumference of the crown band 108, without overlapping the crown edges 420 and 720 and/or the brim edges 422 and 722. This may constitute the largest size of the crown of the hat in an opened position. As the size of the hat is adjusted via the size adjusting mechanism 401 by coupling the outer flap 430 of the crown 104 to the second region 432 of the crown 104 (i.e., by adjusting the outer fastener), it may decrease an overall size of the crown by a suitable amount as described previously with respect to FIGS. 11A-11D. In this closed/fastened position of the hat, the gusset 1202 is no longer extended and may bend or fold as the overlapping of the crown edges 420 and 720 and the brim edges 422 and 722 increases. In a closed state of the hat, the gusset 1202 may remain in an interior of the hat without being visible from an outside of the hat.

While the illustrated embodiment in FIG. 12 shows only one female piece 441 positioned on the second region 432 of the crown that is capable of engaging with the male piece 412 to form a snap closure, the hat may include more than one female piece without departing from the scope of this disclosure. In other examples, instead of a snap, the fastener of the hat may comprise hook and loop fasteners, buttons, hook and eyelets, etc. In yet other examples, the hat resizing may be controlled by using an elastomeric gusset as described above, thereby omitting the fastener completely.

In the illustrated example of FIG. 12, the hat body includes a crown covering fully over the top of a wearer's head (i.e., crown material is provided in all areas of the crown such that no portions of the wearer's head remain exposed to the environment). In other examples, however, a hat body may include a crown that does not cover all of a wearer's head or partially covers the wearer's head within the crown such that a top of the wearer's head may remain exposed to the environment while wearing the hat. It is to be understood that the embodiment with the gusset spanning a crown slit described herein may be included in both styles of the hat with crown fully covering the wearer's head and with crown partially covering the wearer's head.

Moreover, in some examples, the gusset may span the slit as described herein above e.g., with the gusset being positioned between the terminating edges of the crown slit, while in other examples, the slit may form an opening with no material between the terminating edges of the slit.

The features described herein may be provided in various combinations of headwear examples to provide a flexible, robust, and functional hat that performs well in any environment and stands up to heavy use. Although a wide-brimmed hat is illustrated and described, it is to be understood that any one or more of the features described herein may be included in other styles of hats, including, without limitation, a ball cap, a sun fedora, a boonie hat, a capotain, a gat, a hardee hat, a homburg, a panama, a sombrero, a top hat, and/or other suitable head covering.

The disclosure also provides support for a hat, comprising: a crown, and a size adjusting mechanism including a crown slit comprising a first terminal crown edge and a second terminal crown edge, where the first terminal crown edge and the second terminal crown edge extend continuously from a slit termination site of the crown through a bottom circumferential edge of the crown, and where the first terminal crown edge and the second terminal crown edge are configured to overlap by a greater or lesser extent as a size of the crown is adjusted via the size adjusting mechanism. In a first example of the hat, the crown comprises an apex and the slit termination site is at the apex. In a second example of the hat, optionally including the first example, the crown comprises an apex and the slit termination site is offset from the apex. In a third example of the hat, optionally including one or both of the first and second examples, the hat further comprises: a brim coupled along at least a portion of the bottom circumferential edge of the crown. In a fourth example of the hat, optionally including one or more or each of the first through third examples, the crown includes a first flap and a second flap, the first terminal crown edge extending to the bottom circumferential edge of the crown at the first flap and the second terminal crown edge extending to the bottom circumferential edge of the crown at the second flap, and wherein the bottom circumferential edge of the crown is not coupled to the brim at the first flap or the second flap. In a fifth example of the hat, optionally including one or more or each of the first through fourth examples, the brim extends around a circumference of the crown, the brim having a brim slit comprising a first terminal brim edge and a second terminal brim edge, wherein the crown slit and the brim slit collectively form an overall slit that extends continuously from the slit termination site and through an outer brim edge of the brim. In a sixth example of the hat, optionally including one or more or each of the first through fifth examples, the crown slit and the brim slit are not aligned. In a seventh example of the hat, optionally including one or more or each of the first through sixth examples, the hat further comprises: an outer fastening mechanism, a first portion of the outer fastening mechanism positioned on the first flap and a second portion of the outer fastening mechanism positioned at a first inner region of the crown adjacent the second flap. In an eighth example of the hat, optionally including one or more or each of the first through seventh examples, the hat further comprises: an inner fastening mechanism including a third portion positioned on the second flap and a fourth portion positioned at a second inner region of the crown adjacent the first flap. In a ninth example of the hat, optionally including one or more or each of the first through eighth examples, when the first portion is engaged with the second portion and/or when the third portion is engaged with the fourth portion, the first terminal brim edge overlaps the second terminal brim edge and the first terminal crown edge overlaps the second terminal crown edge. In a tenth example of the hat, optionally including one or more or each of the first through ninth examples, the brim is comprised of a sturdy material and the crown is comprised of fabric. In an eleventh example of the hat, optionally including one or more or each of the first through tenth examples, the crown includes an arc extending from the apex of the crown to the bottom circumferential edge of the crown, and wherein the crown slit extends continuously along at least a portion of the arc. In a twelfth example of the hat, optionally including one or more or each of the first through eleventh examples, the crown slit extends continuously along at least 80% of a length of the arc.

The disclosure also provides support for a hat, comprising: a crown, a size adjusting mechanism including a crown slit comprising a first terminal crown edge and a second terminal crown edge, where the first terminal crown edge and the second terminal crown edge extend continuously from a slit termination site of the crown through a bottom circumferential edge of the crown, and where the first terminal crown edge creates a first flap and the second terminal crown edge creates a second flap, and a fastener including a first portion positioned on the first flap and a second portion positioned at a first inner region of the crown adjacent the second flap, where an engagement of the first portion and the second portion of the fastener leads to an overlapping of the first terminal crown edge and the second terminal crown edge by a greater or lesser extent as a size of the crown is adjusted via the size adjusting mechanism. In a first example of the hat, a brim is coupled to the bottom circumferential edge of the crown and extends around a circumference of the crown except at the first flap and the second flap, the brim having a brim slit comprising a first terminal brim edge and a second terminal brim edge, wherein the crown slit and the brim slit collectively form an overall slit that extends continuously from the slit termination site and through an outer brim edge of the brim. In a second example of the hat, optionally including the first example, the slit termination site of the crown includes a region of an overlapping material created by overlapping of the first terminal crown edge and the second terminal crown edge, and wherein the region of overlapping material is mirrored on an outer and inner sides of the crown.

The disclosure also provides support for a hat, comprising: a crown, a size adjusting mechanism including a crown slit comprising a first terminal crown edge and a second terminal crown edge, where the first terminal crown edge and the second terminal crown edge extend continuously from a slit termination site of the crown through a bottom circumferential edge of the crown, and a gusset extending across an opening formed by the crown slit, the gusset including a first edge coupled to the first terminal crown edge and a second edge coupled to the second terminal crown edge such that the crown extends continuously, the first edge and the second edge of the gusset meeting at the slit termination site, where the gusset is configured to fold when the first terminal crown edge and the second terminal crown edge overlap as the hat is resized via the size adjusting mechanism. In a first example of the hat, the hat further comprises: a brim coupled along the bottom circumferential edge of the crown, the brim having a brim slit comprising a first terminal brim edge and a second terminal brim edge, wherein the crown slit and the brim slit collectively form an overall slit that extends continuously from the slit termination site and through an outer brim edge of the brim, and wherein the gusset coupled to the crown slit also extends to the brim slit such that the first edge of the gusset attaches to the first terminal brim edge, the second edge of the gusset attaches to the second terminal brim edge, and a third edge of the gusset extending along the outer brim edge of the brim. In a second example of the hat, optionally including the first example, a width of the gusset decreases in a direction from the third edge of the gusset to the slit termination site of the crown. In a third example of the hat, optionally including one or both of the first and second examples, the gusset is made of an elastomeric material.

The description of embodiments has been presented for purposes of illustration and description. Suitable modifications and variations to the embodiments may be performed in light of the above description. The described headwear features are exemplary in nature, and may include additional elements and/or omit elements. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various headwear and configurations, and other features, functions, and/or properties disclosed.

As used in this application, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural of said elements or steps, unless such exclusion is stated. Furthermore, references to “one embodiment” or “one example” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. The terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements or a particular positional order on their objects. The following claims particularly point out subject matter from the above disclosure that is regarded as novel and non-obvious. 

1. A hat, comprising: a crown; and a size adjusting mechanism including a crown slit comprising a first terminal crown edge and a second terminal crown edge, where the first terminal crown edge and the second terminal crown edge extend continuously from a slit termination site of the crown through a bottom circumferential edge of the crown, and where the first terminal crown edge and the second terminal crown edge are configured to overlap by a greater or lesser extent as a size of the crown is adjusted via the size adjusting mechanism.
 2. The hat of claim 1, wherein the crown comprises an apex and the slit termination site is at the apex.
 3. The hat of claim 1, wherein the crown comprises an apex and the slit termination site is offset from the apex.
 4. The hat of claim 1, further comprising a brim coupled along at least a portion of the bottom circumferential edge of the crown.
 5. The hat of claim 4, wherein the crown includes a first flap and a second flap, the first terminal crown edge extending to the bottom circumferential edge of the crown at the first flap and the second terminal crown edge extending to the bottom circumferential edge of the crown at the second flap, and wherein the bottom circumferential edge of the crown is not coupled to the brim at the first flap or the second flap.
 6. The hat of claim 5, wherein the brim extends around a circumference of the crown, the brim having a brim slit comprising a first terminal brim edge and a second terminal brim edge, wherein the crown slit and the brim slit collectively form an overall slit that extends continuously from the slit termination site and through an outer brim edge of the brim.
 7. The hat of claim 6, wherein the crown slit and the brim slit are not aligned.
 8. The hat of claim 7, further comprising an outer fastening mechanism, a first portion of the outer fastening mechanism positioned on the first flap and a second portion of the outer fastening mechanism positioned at a first inner region of the crown adjacent the second flap.
 9. The hat of claim 8, further comprising an inner fastening mechanism including a third portion positioned on the second flap and a fourth portion positioned at a second inner region of the crown adjacent the first flap.
 10. The hat of claim 9, wherein when the first portion is engaged with the second portion and/or when the third portion is engaged with the fourth portion, the first terminal brim edge overlaps the second terminal brim edge and the first terminal crown edge overlaps the second terminal crown edge.
 11. The hat of claim 4, wherein the brim is comprised of a sturdy material and the crown is comprised of fabric.
 12. The hat of claim 3, wherein the crown includes an arc extending from the apex of the crown to the bottom circumferential edge of the crown, and wherein the crown slit extends continuously along at least a portion of the arc.
 13. The hat of claim 12, wherein the crown slit extends continuously along at least 80% of a length of the arc.
 14. A hat, comprising: a crown; a size adjusting mechanism including a crown slit comprising a first terminal crown edge and a second terminal crown edge, where the first terminal crown edge and the second terminal crown edge extend continuously from a slit termination site of the crown through a bottom circumferential edge of the crown, and where the first terminal crown edge creates a first flap and the second terminal crown edge creates a second flap; and a fastener including a first portion positioned on the first flap and a second portion positioned at a first inner region of the crown adjacent the second flap; where an engagement of the first portion and the second portion of the fastener leads to an overlapping of the first terminal crown edge and the second terminal crown edge by a greater or lesser extent as a size of the crown is adjusted via the size adjusting mechanism.
 15. The hat of claim 14, wherein a brim is coupled to the bottom circumferential edge of the crown and extends around a circumference of the crown except at the first flap and the second flap, the brim having a brim slit comprising a first terminal brim edge and a second terminal brim edge, wherein the crown slit and the brim slit collectively form an overall slit that extends continuously from the slit termination site and through an outer brim edge of the brim.
 16. The hat of claim 14, wherein the slit termination site of the crown includes a region of an overlapping material created by overlapping of the first terminal crown edge and the second terminal crown edge, and wherein the region of overlapping material is mirrored on an outer and inner sides of the crown.
 17. A hat, comprising: a crown; a size adjusting mechanism including a crown slit comprising a first terminal crown edge and a second terminal crown edge, where the first terminal crown edge and the second terminal crown edge extend continuously from a slit termination site of the crown through a bottom circumferential edge of the crown; and a gusset extending across an opening formed by the crown slit, the gusset including a first edge coupled to the first terminal crown edge and a second edge coupled to the second terminal crown edge such that the crown extends continuously, the first edge and the second edge of the gusset meeting at the slit termination site; where the gusset is configured to fold when the first terminal crown edge and the second terminal crown edge overlap as the hat is resized via the size adjusting mechanism.
 18. The hat of claim 17, further comprising a brim coupled along the bottom circumferential edge of the crown, the brim having a brim slit comprising a first terminal brim edge and a second terminal brim edge, wherein the crown slit and the brim slit collectively form an overall slit that extends continuously from the slit termination site and through an outer brim edge of the brim, and wherein the gusset coupled to the crown slit also extends to the brim slit such that the first edge of the gusset attaches to the first terminal brim edge, the second edge of the gusset attaches to the second terminal brim edge, and a third edge of the gusset extending along the outer brim edge of the brim.
 19. The hat of claim 18, wherein a width of the gusset decreases in a direction from the third edge of the gusset to the slit termination site of the crown.
 20. The hat of claim 19, wherein the gusset is made of an elastomeric material. 